Tumble packing apparatus

ABSTRACT

Tumble packing apparatus for filling a case with containers such as damageable, liquid-filled, lightweight plastic containers and the like including: apparatus for discharging containers in a free fall path of travel to a container case, and a cushioning pad which is selectively movable from a removed position into the path of initially charged, free falling containers to temporarily interrupt and cushion the free fall travel of the initial charge of containers before they impact the container case. Mechanism is provided to remove the pad, after a predetermined number of containers have been cushioned, to permit the initial charge of containers to move to a final position within the case and cushion the immediately following containers which fall to fill the case.

United States Patent Pokorney TUMBLE PACKING APPARATUS [75] Inventor:Charles F. Pokorney, Oak Lawn, ll].

[73] Assignee: Koehring Company, Milwaukee,

Wis.

[22] Filed: July 28, 1972 [21] Appl. No.: 276,068

[52] U.S. Cl. 53/59, 53/248 [51] Int. Cl B65b 57/06, B65b 5/00 [58]Field of Search 53/35, 59, 67, 248; 193/7,

[56] References Cited UNITED STATES PATENTS 3,235,052 2/1966 Odell193/32 3,590,981 7/1971 Adrian 193/7 X 3,640,366 2/1972 Ross et a1.193/7 2,686,623 8/1954 Wimmer 53/248 X 2,934,871 5/1960 Watts 3,021,6562/1962 Vries 53/248 [111 3,788,029 1 51 Jan. 29, 1974 PrimaryExaminer-Robert L. Spruill Attorney, Agent, or Firm Learman & McCulloch[5 7] ABSTRACT Tumble packing apparatus for filling a case withcontainers such as damageable, liquid-filled, lightweight plasticcontainers and the like including: apparatus for discharging containersin a free fall path of travel to a container case, and a cushioning padwhich is selectively movable from a removed position into the path ofinitially charged, free falling containers to temporarily interrupt andcushion the free fall travel of the initial charge of containers beforethey impact the container case. Mechanism is provided to remove the pad,after a predetermined number of containers have been cushioned, topermit the initial charge of containers to move to a final positionwithin'the case and cushion the immediately following containers whichfall to fill the case. a

5 Claims, 4 Drawing Figures 350 4s. 50 47 i 54 se as PATENTEDJAN 29 I974sum 2 or 2 TUMBLE PACKING APPARATUS BACKGROUND OF THE INVENTION Thisinvention relates to apparatus for, and a method of, tumble packingcontainers in cases, and more particularly to apparatus for, and amethod of, reducing the impact effect on containers dropped into acontainer case by cushioning the fall of containers tumble packed into acontainer case to eliminate container damage.

Fruit juice, milk, and other liquid products are frequently stored inthin-walled deformable plastic containers having removable closuremembers sealed thereto. The containers are frequently randomly packed,or tumble packed, in container cases for subsequent storage andtransportation.

Tumble packing filled containers in cases typically involves moving astandard size dairy or fruit juice case beneath container dischargemechanism which releases free falling containers. Although dairystandards permit the use of flat-bottom cases for tumble packing, suchcases are not practical in the dairy and fruit juice industries sincesuch cases are not as quickly and economically cleaned. The casesutilized have side and bottom panels incorporating wire or plastic gridsso that water, debris, and spilled container contents can be readilywashed therethrough. Each of the grids or grills has protruding edgeswhich constitute blunt knife edges and, when free falling containersstrike such edges, the impact energy sometimes causes penetration of thecontainers and the closure members or cracking of the containers,resulting in what are known as leakers. It has been discovered thatdamage generally occurs to only the first few containers inasmuch assucceeding containers are protected because they land on the initialcharge of deformable containers already lining the bottom of the case.

Such container damage is vexatious, since filled container cases aregenerally stacked four to five high and leaking containers in uppercases will contaminate the cases and containers below, the coolerstorage area and other floors over which the cases are transported, andcontainer display cases.

Accordingly, it is a primary object of the present invention to providea tumble packing apparatus and method which minimizes or eliminatesdamage to tumble packed containers which free fall into such cases.

It is another object of the present invention to provide a new andimproved method of tumble packing cases by cushioning the free fall ofthe containers into the cases.

It is another object of the present invention to provide tumble packingapparatus which incorporates a fall-breaking pad in, or adjacent, a casebeing filled for cushioning initially charged free falling containersfrom full impact with the grill edges of standard dairy and fruitindustry cases.

It is still another object of the present invention to provide a tumblepacking system which automatically, at proper times, positions aresilient pad in, and withdraws the pad from, the path of containersbeing discharged into a case.

Other objects and advantages of the present invention will becomeapparent to those of ordinary skill in the art as the descriptionthereof proceeds.

SUMMARY OF THE INVENTION Apparatus for tumble'packing articles, such asliquidfilled plastic containers, in article cases and the like,

comprising: frame support means; apparatus thereon for supporting anarticle case at a case filling station; conveying means on the framesupport means for supplying a line of articles to a higher level than acase at the case filling station and releasing them in a free fall pathof travel to the case; means on the frame support means movable in ato-and-fro path of travel between a removed position out of the path ofthe free falling articles, and an operative position in the path of thefree falling articles for interrupting the free fall of at least aportion of them to prevent them from striking sharp edges on the case intheir free fall path of travel; and means on the frame support means formoving the interrupting means in said to-and-fro path between theoperative position and the removed position to permit the interruptedcontainers to finally settle in the case.

The present invention may more readily be understood by reference to theaccompanying drawings, in which:

FIG. 1 is an end elevational view of tumble packing apparatusconstructed according to the present invention, taken along the line l-lof FIG. 2;

FIG. 2 is a top plan view of the tumble packing apparatus illustrated inFIG. 1;

FIG. 3 is an enlarged, perspective plan view of a typical container caseturned on its side to illustrate its grid-like bottom; and I I FIG. 4 isa schematic diagram of a control circuit for controlling the operationof the apparatus illustrated in FIGS. 1 and 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT Referring now more particularlyto FIGS. l and 2, tumble packing apparatus constructed according to thepresent invention includes a framework, generally designated F, havinglongitudinally and laterally spaced pairs of upstanding support rails 10and 12, spanned respectively by vertically spaced rails 14 and 15. Siderails 17 and 18, respectively connect the inner posts 10 and 12.Supported on the side rails 17 and 18 between the upstanding frame rails10 and I2 is a container case conveyor, generally designated 16,including a pair of frame supported endless link chains, schematicallydesignated 22, continuously endlessly driven by a motor M (FIG. 4), forforwardly conveying, in the direction of the arrow a, container cases orreceptacles, generally designated R. Channel guide members 20 aremounted on the side rails 18 for laterally guiding the container cases Rmoved forwardly by the chains 22, to a conveyor case filling station,generally designated 24, where forward movement of the container cases Ron the chains 22 is temporarily interrupted by a stop bar 26 pivotallymounted on the side frame member 18 by a pivot pin 28. The stop 26 ismoved between the nonblocking position, illustrated in solid lines inFIG. 1, and a case blocking position, illustrated in chain lines in FIG.1, by a double-acting, solenoid actuated, fluid operated cylinder 30pivotally mounted on a frame supported pivot pin 31 and having a pistonrod 32, pivotally connected with the stop bar 26 by a pivot pin 33.

Apparatus, generally designated 25, for supplying liquid-filledcontainers 0, typically comprising spinwelded hollow, plastic bodies 32,sealed by cap closure members 34, to the container cases R at the casefilling station 24 includes a flat (table) top conveyor assembly 35, ofthe type disclosed in U.S. Pat. No. 1,966,659, supported by longitudinalside rails 13 spanning the upper ends of the vertical rails 12. Theconveyor assembly 35 includes an endless conveyor member generallydesignated 35c continuously driven by the motor M (FIG. 4) and havingupper and lower runs 35a and 35b. The containers c are fed on the upperrun 35a of conveyor 35c between a pair of parallel guide rails 36, whichare supported on the frame rails 13 by mounting bars 37, to a containerdischarge station 33. The container guide rails 36 include curvilinearforward end portions 36a for directing the containers sidewisely off theflat top conveyor run 35a to a deflector pad 38 mounted on one of theside rails 13 for deflecting the released containers 0 laterally awayfrom the conveyor assembly 35 in a downward path of travel, representedby the arrow d (FIG. 1) toward a case R at the case filling station 24.Apparatus is provided for controlling the discharge of liquid-filledcontainers 0 from the conveyor 35, and includes a normally braked starwheel assembly, generally designated 40, including a star wheel plate 46mounted on a vertical shaft 42, joumaled in frame supported bearings 44,and having peripherally spaced pockets 46a spaced to receive successivecontainers 0 moving on the conveyor run 35a.

Apparatus is provided for normally braking rotation of the star wheelshaft 42 and may comprise a shaft 47 journaled in frame supportedbearings 48 and mounting, at its upper end, a gear 49 drivinglyconnected with a gear 50 fixed to the lower end of the star wheelsupporting shaft 42. A brake drum 54 may be provided on the shaft 47 anda frame supported brake shoe 55 may be normally biased into engagementtherewith by a pair of springs 56 mounted on the frame F. Anelectrically energizable, control solenoid 58 is provided for moving thebrake shoe 55 to a removed, inoperative position, permitting thefree-wheeling of the shaft 47 and the star wheel assembly 40 to permitcontainers 0 to be moved forwardly on the conveyor run 35a into the caseR at the case filling station 24. When the solenoid 58 is deenergized,the star wheel assembly 40 is braked and prevents the further dischargeof containers 0 to the 7 container case R. When the brake solenoid 58 isdeenergized, the star wheel assembly 40 is free to be turned by theadvancing containers c to index a conventional, commerically availableframe supported double register" electronic counter CR. The countertypically may be the Model 49800-405 (49803 prewarn) countermanufactured by Durant Instruments Division of Cutler Hammer, Inc., ofWatertown, Wisconsin, which is mechanically linked to the shaft 47 andis operatively connected in the control circuit (FIG. 4 to control theenergization of the brake solenoid 58 and the release of containers cfrom the container discharge station 33.

A typical industry container case R (FIG. 3) includes side walls 63 anda bottom wall 61 which is made up of plastic grill or grid members 65with exposed blunt edge portions 67 which may penetrate a container cdropped thereagainst in an uninterrupted free fall path of travel fromthe conveyor run 35a. To prevent the containers 0 from being damaged,apparatus is provided for interrupting or cushioning the free fall ofthe initial charge of containers 0 into each case R at the case fillingstation 24 and comprises a vertically inclined base frame member 60supported by the vertical frame rails and mounting a pair of upstandingcarriage-supporting plates 63, spanned by transverse, guide rods 62 onwhich a pad supporting carriage 64 is freely slidably movable between alowered, operative position, illustrated in solid lines in FIG. 1, and araised, removed position, illustrated in chain lines in FIG. 1.Resiliently mounted on the carriage 64 is a resilient pad 66 of softrubber material, preferably in the 40 50 durometer range, which hassufficient strength to support itself in the position in which it isshown in FIG. 1. The pad 66 will give or be deflected slightlydownwardly each time it interrupts the fall of one of the containers c.

Apparatus for reciprocating the carriage 64 and cushioning pad 66between the lowered and raised positions, illustrated in solid and chainlines respectively in FIG. 1, comprises a pressure fluid-operated,double acting, solenoid actuated cylinder 68 mounted on a pair oflongitudinal cross members 67 provided on the plate 60. The cylinder 63includes a piston rod 70 extending through one of the upstandingcarriage supporting plates 63 and connected to the pad mounting carriage64.

Referring now more particularly to FIG. 4, a control circuit foroperating the apparatus disclosed in FIGS. 1 and 2 is schematicallyillustrated and includes a pair of lines L1 and L2 connected across asuitable source of power, such as 110 volt, 60 cycle, current. Connectedacross the lines LI and L2 in line L3 is an electrical motor M forcontinuously driving the flat tabletop conveyor 35 to forwardly delivercontainers 0 to the star wheel assembly 40 and the container dischargestation 33. Connected across the lines L1 and L2 in line L4 is the padlowering solenoid 68a for causing fluid to be directed to the padlowering cylinder 68 in such a manner as to lower the resilientcushioning pad 66 to the cushioning position, illustrated in FIG. 1 inthe path of the free falling containers 0. Also connected in line L4 isa set of limit switch contacts LS-la which are closed when a limitswitch LS-l, mounted on the pivotal case stop bar 26 is engaged by acontainer case R engaging the pivotal stop bar 26 at the case fillingstation 24. Connected in series with the pad lowering solenoid 68a andthe limit switch contacts LS-la are the normally closed contacts 68blwhich are opened when a pad raising solenoid 68b connected in line L5 isenergized. The pad raising solenoid 68b (line L5), when energized, willdirect fluid to the cushioning pad control cylinder 68 in such adirection as to cause the resilient pad 66 to be withdrawn to the raisedposition illustrated in chain lines in FIG. I. Serially connected withthe pad raising solenoid 68b are the normally open contacts CR1 whichare closed when a sufficient number of containers 0 have passed the starwheel 40 to line the bottom of the case R and the counter CR connectedin line L6 across the lines L1 and L2 is incrementally indexed anidentical number of times.

Connected in line L7 across the lines L1 and L2 are the normally openlimit switch contacts LS-lb, which are closed when the limit switch LS-lon the pivotal case stop bar 26 is actuated by a case R arriving at thecase loading station 24, the brake actuating solenoid 58a forwithdrawing the brake 58 to permit the star wheel assembly 40 to berotated by the containers moving on the conveyor 35, and the normallyclosed counter contacts CR3 which open when the counter CR has beenindexed a sufficient number of times to indicate that the case R isfull.

Connected in line L8 across the lines L1 and L2 is a stop bar controlcylinder 30a for moving the pivotal stop bar 26 to the case interruptingposition illustrated in chain lines in FIG. 1 and the normally closedcontacts 30121 which are open when the solenoid 30b (line L9) isenergized. The solenoid 30b (line L9) is energized to retract thepivotal stop bar 26 to the nonblocking position illustrated in solidlines in FIG. 3. Connected in series with the solenoid 30b in line L9are the normally closed limit switch contacts LS-2a which are closedwhen a limit switch LS-2 downstream of the case filling station 24 isenergized by a case moving away from the case filling station 24, andthe normally open counter contacts CR2 which close when a predeterminednumber of containers have been deposited in the case' R to fill thecase.

THE OPERATION The containers 0 are formed, filled, and sealed byapparatus such as that disclosed in United States patent applicationSer. No. 154,058, filed June 17, 1971, and now U.S. Pat. No. 3,744,212which is assigned to the assignee of the present invention.

In the first place, the conveyor chains 22 are driven to move a case Ragainst the pivotal stop bar 26 extending into the path of a case R atthe case filling station 24, and this activates limit switch LS-l. Whenthe limit switch LS-l is actuated, the contacts LS-la (line L4) close toenergize the cushioning pad advance solenoid 68a to lower the cushioningpad 66 in a downwardly inclined path of travel into the container case Rat the case filling station 24 to the position illustrated in FIG. 1. Atthe same time, the contacts LS-lb (line L7) are closed to energize thebrake retract solenoid 58 for retracting the brake 55 and permitting thestar wheel assembly 40 to be freely driven by containers c moving on theconveyor 35. After enough containers c (e.g. 8 10) to line the bottom ofthe case R pass the star wheel assembly 40 and fall into the containercase R, the electronic counter CR signals for retraction of thecushioning pad 66 by closing the contacts CR1 (line L) to energize thepad retract solenoid 68b which retracts the cushioning pad 66 to theinoperative position illustrated in chain lines in FIG. 1. The filledcontainers 0 continue to flow into the container case Rutilizing theinitial charge of containers c as a cushioning layer which now lines thebottom wall 68 of the container case R during the remainder of thefilling operation for that particular case. When the case is filled witha predetermined number of filled containers c, the electronic counter CRwill have been actuated a predetermined additional number of times sothat the normally closed counter contacts CR3 (line L7) open todeenergize the brake solenoid which releases the brake 55 intoengagement with the brake drum S4 and prevents the containers 0 fromturning the star wheel assembly 40 and thus prohibits the furtherpassage of containers 6 on the conveyor 35. When the counter CR hascounted the full complement of containers which are to be delivered tothe case R, the contacts CR2 (line L9) also close to energize theretract solenoid 30b (line L9) which retracts the pivotal case stop 26to the solid line position illustrated in FIG. 1 so that the filledcontainer case R may be moved by the cohveyor chains 22 forwardly in thedirection of the arrow a. Upon exit from the case filling station 24,the container case R trips the limit switch LS-2 to open the limitswitch contacts LS-2a (line L9) and deenergize the stop retract solenoidb. This closes the contacts 30b 1 (line L8) and permits the stop advancesolenoid 30a to again be energized to laterally position the pivotalcase stop 26 in the path of the next succeeding container case R movedto the container filling station 24. The electronic counter CR will havebeen reset and the cycle will again repeat itself when the limit switchLS-l is again actuated by a succeeding case R arriving at the casefilling station 24.

It is to be understood that the drawings and descriptive matter are inall cases to be interpreted as merely illustrative of the principles ofthe invention, rather than as limiting the same in any way, since it iscontemplated that various changes may be made in various elements toachieve like results without departing from the spirit of the inventionor the scope of the appended claims.

What is claimed is:

1. Apparatus for tumble packing articles, such as liquid-filledcontainers, in article cases and the like, comprising:

frame support means iricluding case support means for supporting a caseat a case filling station;

conveying means on said frame support means for supplying articles at alevel higher than a case to be filled at said case filling station andreleasing the articles in a free fall path of travel to said case;

cushioning pad means on said frame support means,

which is movable in a to-and-fro path of travel between a removedposition, out of the path of the free falling articles and removed fromthe case, and an operative interrupting position, within said case andin the path of the free falling articles, for interrupting the free fallof at least a portion of the falling articles;

means on said frame support means for moving said cushioning pad meansin said to-and-fro path between said operative and removed positionsincluding means for moving said cushioning pad means to said removedposition after a predetermined number of articles have been released tosaid cushioning pad means;

means for interrupting the release of articles from said conveyor meansafter a predetermined number of articles have been released; and I meansfor operating said moving means to withdraw said cushioning pad means tosaid removed position after a lesser predetermined number of articleshave been released to said pad means.

2. Apparatus as set forth in claim 1 wherein said interrupting meanscomprises:

a carriage supported on said frame for movement in a to-and-fro path oftravel toward and away from a case at said case filling station;

a cushioning pad resiliently supported on the carriage, for movement insaid to-and-fro path of travel.

3. The apparatus set forth in claim 2 wherein said carriage moves in avertically inclined path of travel.

7 4. Apparatus for tumble packing articles, such as liquid-filledcontainers, in article cases and the like, comprising:

frame support means including case support means for supporting a caseat a case filling station;

conveying means on said frame support means for supplying articles at alevel higher than a case to be filled at said case filling station andreleasing the articles in a free fall path of travel to said case;

interrupting means on said frame support means movable in a to-and-fropath of travel between a removed position out of the path of the freefalling articles and an operative interrupting position in the path ofthe free falling articles for interrupting the free fall of at least aportion of the falling articles;

means on said frame support means for moving' said interrupting means insaid to-and-fro path between said operative and removed positionsincluding means for moving said interrupting means to said removedposition after a predetermined number of articles have been released tosaid interrupting means;

control circuit means adapted to be connected to a source of electricalpower;

means in said control circuit responsive to a case being positioned atsaid case filling station for operating said conveying means to supplyarticles for tumble packing and to move said interrupting means to saidinterrupting position; and

means in said control circuit means, responsive to a predeterminednumber of articles being moved toward said case, for moving saidinterrupting means to said removed position.

5. The apparatus set forth in claim 4 including means responsive to anadditional predetermined number of articles being forwarded toward saidcase to render said article conveying means inoperable until anothercase is positioned at the case filling station.

1. Apparatus for tumble packing articles, such as liquid-filledcontainers, in article cases and the like, comprising: frame supportmeans including case support means for supporting a case at a casefilling station; conveying means on said frame support means forsupplying articles at a level higher than a case to be filled at saidcase filling station and releasing the articles in a free fall path oftravel to said case; cushioning pad means on said frame support means,which is movable in a to-and-fro path of travel between a removedposition, out of the path of the free falling articles and removed fromthe case, and an operative interrupting position, within said case andin the path of the free falling articles, for interrupting the free fallof at least a portion of the falling articles; means on said framesupport means for moving said cushioning pad means in said to-and-fropath between said operative and removed positions including means formoving said cushioning pad means to said removed position after apredetermined number of articles have been released to said cushioningpad means; means for interrupting the release of articles from saidconveyor means after a predetermined number of articles have beenreleased; and means for operating said moving means to withdraw saidcushioning pad means to said removed position after a lesserpredetermined number of articles have been released to said pad means.2. Apparatus as set forth in claim 1 wherein said interrupting meanscomprises: a carriage supported on said frame for movement in ato-and-fro path of travel toward and away from a case at said casefilling station; a cushioning pad resiliently supported on the carriage,for movement in said to-and-fro path of travel.
 3. The apparatus setforth in claim 2 wherein said carriage moves in a vertically inclinedpath of travel.
 4. Apparatus for tumble packing articles, such asliquid-filled containers, in article cases and the like, comprising:frame support means including case support means for supporting a caseat a case filling station; conveying means on said frame support meansfor supplying articles at a level higher than a case to be filled atsaid case filling station and releasing the articles in a free fall pathof travel to said case; interrupting means on said frame support meansmovable in a to-and-fro path of travel between a removed position out ofthe path of the free falling articles and an operative interruptingposition in the path of the free falling articles for interrupting thefree fall of at least a portion of the falling articles; means on saidframe support means for moving said interrupting means in saidto-and-fro path between said operative and removed positions includingmeans for moving said interrupting means to said removed position aftera predetermined number of articles have been released to saidinterrupting means; control circuit means adapted to be connected to asource of electrical power; means in said control circuit responsive toa case being positioned at said case filling station for operating saidconveying means to supply articles for tumble packing and to move saidinterrupting means to said interrupting position; and means in saidcontrol circuit means, responsive to a predetermined number of articlesbeing moved toward said case, for moving said interrupting means to saidremoved position.
 5. The apparatus set forth in claim 4 including meansresponsive to an additional predetermined number of articles beingforwarded toward said case to render said article conveying meansinoperable until another case is positioned at the case filling station.